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Foundrymen's Primer 



BY 



WALTER H. WANGELIN, 



BELLEVILLE, ILL. 



I Treatise on the Chemical Constituents 
of Iron, and Methods of Calculating 
the Mixtures of Iron by Analysis 





• 


,Ll6RAKY0f CC 


Two Copies 


Received 


: JAN 18 


1905 


Gopyngni tniry 

C^LASS «- XXc, Not 

/ d 7 £ 5 

COPY B» 




PREFACE. 



<* 






The object of this Primer is to give the 
foundrymen a good general idea of the effects of 
thfi varies different elements, generally contained 
in iron, upon each other and npon the iron, and 
to give the causes that produce different fractures 
in iron. 

The object is, further, to show that the 
fracture of iron is misleading and that the cor- 
rect way is to have the analysis of the iron and 
work by that and not by the fracture. 

To accomplish this several methods have 
also been given to calculate the mixture by analy- 
sis. 

The writer has tried to make the matter 
plain to all readers, and it may seem as if there 
was a repetition of some statements, if so, it is to 
be hoped that these will be well impressed upon 
the mind of the reader. 



INTRODUCTION. 

Gentlemen : 

These pages contain a valuable treatise on Iroa 
and Calculating the Mixture of Iron by Analysis. 
I have tried to make it plain to you why you 
should make the mixture of iron by analysis and 
not by the fracture. Not only that, I have gone 
further, and have given you several methods of 
how to figure the mixture by analysis. This no 
one, to my knowledge, has ever done, and it i3 
probable that the lack of this knowledge is the 
reason why the use of analysis in making the 
mixture is not more general. 

It will not be necessary for you to erect a 
costly laboratory and employ an expert chemist. 
I have a complete laboratory for accurate work 
and make it a business to make the analysis for 
foundries. 

I have foundry experience, have the best 
of help associated with me, and have made the 
analysis and mixture for years for the largest 
foundries in the United States, and, if necessar3% 
could furnish the best of reference. I am doing 
the analytical work for very many foundries all 
over the United States, and if you are not on the 
list, I would be pleased to have you, whether you 
use one car of iron a month or one a day. 

I am about to publish a large treatise on iron, 
of which these pases will be a part. Iwould, 



therefore, be pleased to have you write me your 
opinion, good or bad, about these pages, and tell 
me if there is anything that is not clear or that 
you do not understand. I will also be pleased to 
have you tell me what information, not included 
in these pages, that you would like to see in a 
larger treatise. 

I want to publish a treatise that in as few 
words as possible will give just such information 
that is not well understood by the foundrymen. 
I want my laboratory to do the chemical work 
for most all the foundries in the United States, 
and want my laboratory to be known as the most 
accurate and rapid for all practical purposes. 

Send me your samples and let me hear from 
you. Yours truly. 

WAI/TEK H. WANGELIN", 

Belleville. III. 



NOMENCLATURE. 

Iron is a simple substance and one of the ele- 
ments of chemistry. In its pure state it is found 
only in laboratories and never in every-day life. 
When we speak of an article being made of iron, 
we do not mean that it is made of pure iron, 
but iron containing the impurities that it gen- 
erally contains. These impurities are mainly 
Carbon, Silicon Sulphur, Phosphorus and Man- 
ganese. 

Pure iron would not be as valuable in com- 
merce as the impure. These impurities, the 
amounts of each and their relation towards each 
other is what determines the value of the iron. 

In nature iron is found in combination with 
other substances and forms minerals and ores 
which are treated in Blast-furnaces. 

PIG IRON AND SOWS. 

Iron, when made in the blast furnace, is in 
the molten state, and must be cast "into molds 
or some shapes, so that it can be handled and 
remelted. In practice the iron is cast in open 
sand. A gutter is made from the furnace in the 
sand-casting bed. From the side of this gutter 
smaller gutters or molds are made and the iron 
feeds into these. 

It must have reminded some one of a sow 
nursing its little pigs and, therefore, gave the 
name of sow to the large gutters and pigs to the 
little ones; hence the name of pig iron and sow. 



—6— 

CHILLED MOLDS. 

As the iron runs into the sand bed some of 
the sand adheres to the iron, so that pig iron 
has more or less sand attached to it. This sand 
is detrimental to some processes in which iron 
is used, and, to overcome this, molds of iron 
are used and the iron from the blast furnace 
run into them. Iron is a good conductor of heat, 
and the molten iron east into these iron molds 
cools or chills, and hence the iron is called Iron 
Cast into Chilled Molds. 

BASIC IRON. 

The process in which the sand on the pig is 
detrimental, and for which the iron is cast into 
chilled molds is the Basic Open Hearth Steel 
process. Some persons call the iron cast into 
iron molds, basic iron. This is wrong. While it 
is true that iron for the basic process is cast into 
iron molds, still any iron could be cast into iron 
molds. 

The iron best adapted for the Basic steel 
process should contain these impurities within 
certain limits, and it is best to call iron within 
these limits Basic Iron. . 

BESSEMER AND OFF BESSEMER IRON. 

There is a process of making steel invented 
by a man called Bessemer, and hence the name 
Bessemer Process. In this process the Phospho- 
rus should not be above .10 per cent., and hence 
all iron as low as . 10 per cent., or lower, in Phos- 



phorus is called Bessemer Iron. Sometimes an 
iron contains a little more than this amount, 
say .10 per cent to .20 per cent Phosphorus. This 
iron is often called Off-Bessemer Iron. 

HOT BLAST AND COLD BLAST. 

In former days the blast used in the blast 
furnace was the ordinary air. Nowadays the 
blast is heated before entering the furnace. To 
distinguish between the two, the iron made with 
the unheated blast is called Cold Blast Iron. 

WROUGHT IRON. 

When Iron is treated in a puddling furnace 
and most of the impurities are gotten rid of, so 
that it can be worked and forged, it is called 
Wrought Iron. 

STEEL. 

When iron is treated in any other way than 
in the puddling process, and most of the impuri- 
ties are gotten rid of, it is called steel. The 
analysis of steel varies, as there are many kinds, 
depending upon the use that it is to be put to. 
According to the use of the steel is put to and ac* 
cording to the. name the maker sees fit to give 
it, we have any amount of steels. 

CAST IRON. 

When pig iron is melted and poured into 
some castings,. it is called cast iron. Some cast- 
ings are used for stove plate and some for ma- 



cfhinery castings. The quality of the iron taken 
for stove plate and machinery castings is differ 
e:it, as one is a light casting and the other 
heavy^ and so the two kinds of scrap iron are 
kept separate, one being sold as stove plate scrap 
and the other as machinery scrap. 

MALLEABLE IRON. 

When cast iron is treated after it has been 
cast so that it becomes malleable, it is called 
Malleable Iron. 

SILICA AM) SILICON. 

The word Silicon is used by chemists and 
foundrymen. Notice the spelling of the word. 
The last two letters are "on.*' This is an ele- 
ment in chemistry, a simple substance. This cle- 
ment can combine with other elements and form 
other substances. In the cupola, for instance, 
some of it combines with the oxygen of the air, 
and goes into the slag. This combination of 
Silicon and Oxygen forms sand, or often called 
Silica. Notice that the word ends in "a," and 
not in "on." Silicon (with an ending of "on") is 
the element that we speak of in iron, while the 
white sand and rock is called Silica (ending in 
the letter "a"). Many persons do not use these 
words correctly . 



-9— 



METALLURY OF IRON. 

Iron made in the blast furnace always con- 
\ tains impurities, the amount of each depending 
upon the materials used and the working of the 
furnace. The main impurities to be considered 
are Carbon, Silicon, Sulphur, Phosphorus and 
Manganese. These impurities mentioned are 
elements of chemistry, and so will be called eler 
ments. instead of impurities. 
CAEBOX AND SILICON. 

Iron contains, when other elements are ab- 
sent, about 4.5 per cent of Carbon. If Manga- 
nese is present then the iron can contain more 
Carbon, but all other elements make the iron 
contain less Carbon. 

Iron and Carbon form a white metal. The 
Carbon is all combined. The presence of Sul- 
phur, Phosphorus and Manganese helps to com- 
} bine the Carbon and make a white iron. 

Silicon is the only element (of those consid- 
f ered) which does not help to combine the Car- 
\ bon with the iron. Silicon in the iron will cause 
i the iron to take up less Carbon, and the more 
j Silicon the iron contains the less will be the 
Carbon. Silicon also acts in another way. It 
;l not only causes the iron to take up less Carbon, 
but some of that which it contains is thrown 
I out in little flakes, while the iron is cooling, dis- 
tributing these flakes through the iron, partly 
in crystallized form and partly in an uncrystal- 



—10— 

lized form. These forms are generally called 
Graphite and causes the iron to look grey. 

Iron, when melted, contains all the Carbon in 
the sombined slate. Should some of the Carbon 
have been thrown out, on cooling, as Graphite, 
it would again combine as soon as remelted. No 
matter how much Graphite an iron contains, 
on melting it, this Graphite again changes over 
to Combined Carbon. 

Iron, when melted, contains all the Carbon in 
the combined state and may also contain some 
Silicon, but not enough to counteract other ele- 
ments and tendencies to hold the' Carbon com- 
bined, so that on cooling there is formed a white, 
hard iron, that is brittle and has no strength. 

Iron, when melted, may contain enough Sili- 
con to counteract the other elements and ten- 
dencies to hold the Carbon as Combined Carbon 
and upon cooling some of' this carbon is thrown 
out as Graphite, producing a strong, close- 
grained iron. 

Iron, when melted, may increase still further 
in Silicon, so that the greater part of the Carbon 
is thrown out on cooling at Graphite and form a 
very c oft gray iron. 

Iron, when melted, can. however, contain but 
a limited amount of Carbon and Silicon. We have 
seen that the amount of Carbon thrown out as 
Graphite upo n cooling increased as the Silicon 
increased. The Carbon >eemod to be dissolved 
in iron in presence of Silicon and held there as 



—11— 

long as the iron was melted and hot, but could 
not hold it however on cooling. If the Silicon is 
still further increased, the iron can not hold the 
Carbon, even in the molten state, and the 
Graphite is thrown out in the molten iron and 
rises to the surface, decreasing the amount of 
Carbon in the iron. This Graphite rising to the 
surface is called Kish. 

Iron containing only Carbon can contain as 
high as 4.5 per cent., is all combined and 
forms a white iron and is hard. Silicon will cause 
some of the Carbon to be thrown out as Graphite 
upon cooling to form grey iron. The Total Carbon 
is the same, only some being combined and the 
rest being present as Graphite. When the 
amount of Silicon increases, so that the molten 
iron cannot hold the Carbon in presence of this 
Silicon, the Total Carbon decreases, and we have 
5-6 per cent. Silicon iron, looking white, on ac- 
count of lack of Carbon, and a 10 per cent. Sili- 
con contains only about 1 per cent, of Carbon. 
This Carbon is present almost entirely as Graph- 
ite, but on account of the lack of Carbon the iron 
is white and weak, but is soft. 

Iron that is white and hard on account of low 
Silicon and high Carbon has a different fracture 
and appearance than iron that is white and soft 
on account of high Silicon and low Carbon. 

Carbon makes the molten iron fluid; the same 
can be said of Silicon. Silicon -can combine with 
iron in any proportion and we have Ferro-Sil'con, 
containing 75 per cet of Silicon. 



—1-2— 

It can readily be seen that Silicon plays a 
very important part, and how necessary it is to 
know the amount of Silicon in iron and in the 
castings. 

SULPHUR. 

Sulphur makes the iron brittle and red short 
and makes it run very sluggish and thick. Sul- 
phur tends to make the iron take up less Car- 
bon, it combines the Carbon in the iron and 
makes it white. In melting iron with coke the 
iron takes up the Sulphur in the coke to a great 
extent, so that the castings will contain more 
Sulphur on this account. 

MANGANESE'. 

Manganese causes the iron to take up more 
Carbon. It combines this Carbon and makes the 
iron white. An iron containing 80 per cent of 
Manganese contains about 8 per cent of Carbon. 
Manganese 'has, however, more attraction for the 
Sulphur than iron has, and combines with it 
and neutralizes the effect of the Sulphur. The 
Sulphur and the Manganese unite and often rise 
to the surface of the molten metal, decreasing 
the amount of each thereby and purifying the 
metal. For this reason molten iron high in Sul- 
phur is dirtv, the combination rising to the sur- 
face. It can, therefore, occur that by taking an 
iron, that is bar;! and white on account of Sul- 
phur, and melting it with an iron, hard on ac- 



—13— 

count of Manganese, that a good grey iron is 
produced. 

Iron that contains Manganese is white and it 
looks like the white of a mirror, and hence some 
German gave it that name. The German name 
for a mirror is Spiegel, and hence it is called 
Spiegel Eisen. Lately an iron is made that con- 
tains more Manganese — in fact, more Manga- 
nese than iron. To designate this, and because 
eveiything must have a name, all iron contain- 
ing a smaller amount of Manganese, say up to 
30 per cent of Manganese, is called Spiegel Iron, 
and if it contains more it is called Ferro-Man- 
ganese, the word Ferro meaning iron. Spiegel 
Eisen is generally made to contain about 20 per 
cent and Ferro Manganese about 80 per cent 
Manganese. In buying either, the analysis 
should always be checked up. 

Ferro-Manganese can be bought broken into 
small pieces or ground. It is a good article to 
have around the foundry, for reasons explained 
above, namely: It combines with the Sulphur 
and rises to the surface, thus decreasing the 
amount of Sulphur and purifying the iron. It 
combines with the Sulphur that does not rise to 
the surface and neutralizes its bad effect. The 
Sulphur being thus reduced, the Silicon which 
was required to counteract the bad effects of 
the Sulphur is free to act upon the Carbon, and 
thus clirectlv and indirectly the addition of Man- 



—14— 

ganese when Sulphur is present makes an iron 
softer, more grey, etc., etc. 

When Sulphur is not present to a great ex- 
tent, and the iron is too open, Manganese will 
combine the Carbon and make it a closed grain 
and stronger iron. 

Manganese, therefore, softens the iron in one 
case, and under different condition hardens it. 
By knowing the analysis of the iron, the foun- 
drymen can tell whether the addition of Man- 
ganese will be beneficial or not and the amount 
required. 

It must not be supposed, however, like the 
Indian who took some medicine that little does 
good, that more would do heap good. The 
amount of Manganese added, or whether any 
should be added, depends, of course, upon the 
amount of Sulphur, and this can and should 
always be ascertained by analysis. 

Most of the irons in the United States con- 
tain between .50 per cent and 1.00 per cent of 
Manganese, which is about the amount required 
for the general run of castings. If the iron con- 
tains less, then Manganese should be added. 
Some irons now made contain between 2.00 per 
cent and 3.00 per cent of Manganese, and can 
be ust 1 to mix with low Manganese irons or 
irons thai contain Sulphur. It is necessary, of 
course, to have these irons analyzed to know just 
what ilicv contain. 



—15— 

PHOSPHOKUS. 

Phosphorus combines the Carbon and makes 
makes the iron sensitive to sudden strains, A 
pillar of a house, for instance, that is high in 
Phosphorus will carry the load easily, but it 
apt to break when a heavy wagon runs along the 
street. 

Phosphorus combines the Carbon and makes 
the iron white, and the Combined Carbon again 
makes the Phosphorus act stronger. Silicon 
counteracts the action of the Phosphorus indi- 
rectly by decreasing the combined Carbon. Phos- 
phorus makes the iron very fluid, and for that 
reason it is well liked, provided that it does not 
contain too much. For stove plate the Phospho- 
rus runs as high as .90 per cent to 1.00 per cent, 
while in good machine castings it is never so 
high. It is, therefore, very important to know 
the Phosphor-is of the iron, and every car should 
be analyzed. 

Amounts of Different Elements May Vary in 
Good Castings 

The action of* any one element depends not 
only upon the amount present, but whether 
J some other elements are present, and the 
| amount of these. For instance, as explained^ a 
casting may be high in Sulphur, but still be a 
good casting, because it contains Manganese, 
while the same castings without Manganese 
would be worth nothing. Silicon in iron can be 



—16— 

increased or decreased, as the presence of other 
elements may require, so that it can readily be 
seen that there are a nnjmber of combinations 
that can be made and have good results. This 
of course, can only be done intelligently and 
correctly by knowing the analysis of the iron. 

FRACTURE OF IRON. 

Take a ladle of iron and pour several castings. 
One in a dry sand mold ; another in a green sand 
mold, making the casting rather large in all di- 
mensions, and gradually decreasing to a thin 
stove plate and one cast against a chill. 

The molten iron is alike and has the same in- 
gredients. Still, upon breaking the cold cast- 
ings, we find a vast difference in the fracture. 
The large and dry sand casting? are open 
grain and look like a number one iron, but as 
the castings decrease in size the fracture be- 
comes closer and the iron is harder, and stove 
plate is probably white and cannot be drilled, 
and the casting against the chill is white and 
hard. 

Xnw. if what has been said above about the 
chemical constituents of iron is true, then these 
castings should all be alike, or else there is some 
other action that we have not taken into ac- 
count. We analyze these castings and find the 
total Carbon. Silicon. Sulphur, "Phosphorus and 
Manganese are the same, but the state of the 1 



—33— 

of course, is nonsensical talk. Did a foundry 
ever make $-±00 worth of castings and not have 
them examined? Every casting is examined, and 
when it does not suit the party, they will, reject 
the casting. Foundrymen should always have 
each car of iron checked up for Silicon and 
Phosphorous, and ,if the occasion requires, for 
Sulphur and Manganese. 



GOKE. 

a Every foundry should use good coke. As to the 
analysis, this is deceiving. The cokes that have 
-the least ash and most Carbon are not necessa- 
rily the best. The coke should not have too much 
ash, but the most important part of coke, to 
get a hot iron is the density and structure. 
>An open, porous coke does not give the heat 
jof a dense coke. An open coke requires less 
P blast. The Sulphur in the coke is important, 
! and it is well to analyze the coke for Sulphur, as 
I most of it goes into the iron, and a high Sulphur 
I coke will, of course, raise the Sulphur in the 
pasting. 



— 34— 

Calculating the Mixture 
by Analysis. 

One great drawback in making the mixture 
by analysis was not only the lack of knowledge 
of the effects the different elements had upon 
the iron, but the lack of information as to how 
to calculate the amounts of the different irons 
when the analysis had been made. 

The following methods of calculating will 
show the foundrymen how-to mix the irons, and 
it • is hoped will cause many foundrymen to 
change over from the old way of making the 
mixture by fracture to the only correct way of 
having each car analysed and working by this 
analysis : 

When one figures that a car of iron contains, 
as a rule, twenty-five tons, and then divides the 
cost of analysis by this to see the cost per ton, it 
can easily be seen that it pays well to have an- 
alysis made. The proofs of this are so numer- 
ous that when a foundry once starts to have an- 
alyses made, the advantages will be so many 
that they will be surprised that they did not 
start long ago. The saving to a foundry using 
analysis over the time when they did not have 
the iron checked up and analyzed is often aston- 
ishingly great. Aside from the money question, 
it has been clearly shown that the only correct 
way to make the mixture of iron is by analysis. 



—35— 

Calculating the Mixture of Iron for Silicon, 
When Two Irons are Used. 

When iron is melted in a cupola it loses some 
of its Silicon by oxidation. The amount differs 
in different cupolas, depending upon the mix- 
ture, the size of the cupola, the blasts etc. 
Knowing the average Silicon of the mixture and 
the Silicon of the molten iron, the difference 
will be the loss in melting. It is an easy matter 
to ascertain this. This loss must always be 
added to the amount of Silicon the casting is to 
' 'contain, which will give us the amount of Sili— 
:-on the mixture should contain. 

Let us suppose that this is .30 per cent and the 
casting is to be a machine casting containing 
L.80 per cent Silicon, then the mixture must 
contain 1.80 plus .3, equaling 2.10 per cent Sil- 
con. 

* Let us suppose that we have two irons in the 
rard containing 1.50 per cent Silicon and 2.40 
per cent Silicon and we want to make a mixture 
of 2.10 per cent Silicon. 

I If the mixture should contain 2.10 per cent 
aind the low Silicon iron contains 1.50 per cent 
Silicon, then, by subtracting 1.50 per cent from 
2.10 per cent, we have .60 per cent, the amount 
that the low Silicon iron requires to bring it up 
to the mix. 

If the mixture should contain 2.10 per cent 
and the high Silicon iron contains 2.40 per cent, 






—36— 

then, by subtracting 2.10 per cent from 2.40 per 
cent, we have .30 per cent, the amount that the 
high Silicon iron has too much. 

For every part of low Silicon iron used, we 
have .60 per cent too little, and must add so 
much of the high Silicon iron to make up this 
.60' per cent. If we use one part of the high, we 
have only .30 per cent too much, so that it re- 
quires as many parts of the high as it takes to 
make .60 per cent. Now, .60 per cent divided 
by .30 per cent is equal to 2, so that it takes 2 
parts of the high to one part of the low. 

Proof : 

1 part of 1.50 per cent equals 1.50 per cent. 

2 " " 2.40 " " u 4.80 " " 

3 " mix (or 2.10 per cent) " 6.30 " " 

One part of the mix would contain 2.10 jpei 
cent Silicon. J 

Again, if for every part of high Silicon iroi 
we have .30 per cent too much, then we must 
use as many parts of a low Silicon iron, so that 
the amount too little is equal to .30 per cent. 
'Now, if we use one part of low, we have .60 per 
cent too little. We see then that we must use 
less. We must use so many parts so that multi- 
plied by .60 per cent it makes .30 per cent. Di- 
viding .30 per cent by .60 per cent, we have .50 



—37— 

times, so that we take .50 parts of the low to 

every part of the high. 

Proof: 

1 part of 2 40 per cent equals 2.40 per cent. 
.50 " " 1.50 " " " .75 " " 

1 50 "mix 2.10 " " " 3.15 # " 

Again, if it takes 1 part of the low and 2 
parts of the high to make 3 parts of the mix- 
ture, thn to make 1 part of the mixture, it 
would take 1 divided by 3 of the low Silicon iron 
and 2-3 of 1 of the high, so that we have .333 
parts of the low and .666 parts of the high. 

Thus we have our mixture given in how many 
parts of the high to one part of the low. How 
many of the low to one part of the high, and 
how many of each to mak one part? We can 
take as many parts as we like. Suppose we call 
a part a pound; then we multiply the number 
of parts by whatever number of pounds we want 
to take. 

For instance: If we want to make a mix of 
500 pounds, we see that we must take 500 times 
.333 of the low Silicon and 50i0 times .666 of 
the high Silicon iron, which would be 166 
pounds of low and 333 pounds of high. Or, if it 
takes 3 parts to make the mix, then in 500 
pounds, 1 part would be 500 divided by 3, which 
is 166, an the other would be 2 times 166, or 
500 pounds, less 166, which would be 333 pounds. 
In practice we would (as we do not weigh closer 



—38— 

than 50 pounds) call this 150 of the low and 35C 
of the high. This would make the Silicon a lit- 
tle higher, but it would be as close as we gener- 
ally weigh. 

We have then all we need in a little calculat- 
ing of subtraction and division. Looking ovei 
our figures, we find that we have the following 
rule: 

RULE. Subtract the Lower Silicon Iron Froi 
the Amount of the Mixture, and the Amount 
of the Mixture From the High Silicon Iron 1 
Divide one Difference by the Other and thi 
Answer Will be the Number of Parts of th< 
Divisor to One Part of the Dividend. 
Above example the 

Mixture 2.10 per cent. High 2.40 per cent. 
Low Mix Si. 1.50 " " Mix. 2.10 " " 

.60 " " .30 " " 

.30). 60 (2 .60). 300 (.5 

60 300 

The low difference is .50 per cent and thi 
high difference is .30 per cent. When we divid 
.60 per cent, we get amount of high to 1 of low 
which is 2, and when we divide the .30' pr cen 
we get the amount of low to 1 of high, which 1 
.50. The number you divide is the number yo, 
get one part of. 



—39— 

This rule is very simple. In the example 
taken the figures divided evenly. This was done 
to explain easier. In practice this does not al- 
ways come out that way. 

To further illustrate the method of making 
the mixture, let us take another example. We 
have two irons, one of 3.40 per cent Silicon and 
the other 2.00 per cent Silicon, and the mixture 
ic to contain 2.50 per cent Silicon. 

Applying the rule and, for simplicity sake, 
dropping the per cent Silicon, we have the fol- 



lowing calculations: 








High 3.40 Mix 2.50 
Mix 2.50 Low 3.00 


.50). 90(1. 8 
50 




90). 50 (.555 
450 


.90 .50 


400 
400 




500 
450 


1 part of 3.40 equals 3.40 
1.8 ;t " 2.00 " 3.60 


1 part of 

.55 " " 


2.00 
3.40 


equals 2.00 
" 1.88 



2.8 •' " 2 50 " 7.00 1.55 " " 2.50 " 3.88 

If it takes 1 part of 3.40 per cent iron and 
1.8 part of 2.00 per cent iron, or a total of 2.8 
parts to make the mix, then, if we want to make 
a mix of say 560 pounds, 1 part would be equal 
to 560 pounds, divided by 2,.8, which would be 200 
pounds; the amount of the 3.40 per cent iron, 
and the difference of 560 and 200, which is 360 
pounds, would be the amount of the 2.00 per 
cent iron. The amount of 2.00' per cent iron 
could also be obtained by taking 1.8 times 1 



—40— 

part or 1.8 times 200 pounds, which is 360 
pounds. If, instead of having the mix be equal 
to 560 pounds, it might have been say 1000, or 
any other number. Whatever the amount, the 
calculation would be similar by dividing the 
amount by the total number of parts, which in 
this instance is 2.8, and subtracting the result 
from 1000 to obtain the amount of the other 
iron. 

Calculating the Mixture of Iron for Silicon 
When More Than Two Irons are to be Used. 

When we have two irons we can make but 
one mix. When we have three irons, so that one 
is higher than the mix, or vice versa, then any 
amount of mixtures can be made. For two of 
them can be taken as above and iform a mix. 
Then one of these two irons and the third can 
form a mix, and the proportion of these mixes 
that can be taken to make the mixture is indefi- 
nite. 

Hence, in making a mixture with more than 
two irons," one must assume a given amount of 
some of them. 



Calculating the Mixture of Irou for Silicon, 
When More Than Two Irons are to be Used, 
and the Amount of Iron Assumed Does Not 
Equal to the Total Weight of the Mixture. 

If the mixture is to contain, say 1000 pounds 
at 2.50 per cent Silicon, then the 1000 pounds 
• would contain 1000 times 2.50 per cent Silicon, 
which is equal to 2500 per cent Silicon. If the 
mixture was to contain 600 pounds, then the 
total mix would contain 600 times 2.50 per cent 
Silicon, which is equal to 1500 per cent Silicon. 

The total amount of Silicon a mixture con- 
tains is obtained by multiplying the average 
amount of Silicon the mixture contains "by the 
number of pounds in the mixture. 

Let us suppose that we have a mixture of 
1000 pounds of 2.50 per cent Silicon, using 300 
pounds of gates at 2.20 per cent Silicon, 20O 
pounds of 2.00 per cent Silicon iron, 300 pounds 
of 3.40 pr cent Silicon iron, and the balance of 
scrap iron, containing 1.75 per cent Silicon, and 
as much more of the above-named irons as is 
necessary to make the correct mixture. 

For simplicity sake, we will omit the per cent 
Silicon in calculating, assuming for instance, 
that when we say 2.50 we mean 2.50 per cent 
Silicon. 



—42— 

We then have: 

300 of 2. 20 equals 660 
200 of 2.00 equals 400 
300 of 3.40 equals 1020 



\ 



800 2080 

1000 of 2. 50 equals 2500 



200 420 

Average of 2.10. 

If the mix is to be lOOOi pounds at 2.50, then 
the total amount will "be 1000 times 2.50, equal to 
2500. We have in the assumed mix 800 pounds | 
of iron, the total Silicon of which is equal to 
2080, so hat we must add 200 pounds that will 
have a total Silicon of 420. Dividing 420 by 200,1 
we have 2.10, which is the average amount of} 
Silicon the 420 pounds must contain. 

We now have the problem of making a mix- 
ture of 420 pounds at 2.10 per cent Silicon, using 
the 1.75 per cent iron and 3.40 per cent iron. 

U>ing the rule for making the mixture of two! 

irons we have the following : 

High 3.40 Mix 2.10 .35)1.30(3.714 

Low 2.10 Low 1.75 1.05 



1.30 .35 250 

245 

1 part of 3.40 equals 3 40 
3.714 " " 1.75 " 6.4995 



4.714 " " 2.10 " 9.8995 



—43— 

Or one part of 3.40 and 3.714 parts of 1.75 
makes 4.714 parts of the 2.10 mixture. If the 
amount of the mixture is to be 200 pounds, then 
one part will be 200, divided by 4.714 equals to 
42.44 pounds, the amount of the 3.40 iron re- 
quired, and 200 pounds, less 43.44 pounls, equals 
to 157.56 pounds, equals the amount of 1.75 iron 
required. Adding the 42.44 pounds of 3.40 iron 
to the originally assumed 300 pounds, we have 
the following for our mixture: 
300 pounds gates @ 2.20 equals . . 660 
200i pounds of iron @ 2.00 equals. . 400 
157.56 pounds or iron @ 1.75 equals. . 276.85 
342.44 pounds of iron @ 3.40 equals. .1162.23 



1000.00 2499.07 

This would give us a mixture of 2.50, but as 
we do not weigh, as a rule, closer than 50 pounds, 
we change the 157.56 to 150 and the 342,44 to 
350. 

Calculating the Mixture of Iron For Silicon, 
When More Than Two Irons are to be Used, 
and the Amount of Iron Assumed Equals to 
the Total Weight of the Mixture, but the 
Total Silicon is Either Greater or Less Than 
the Total Mixture Should Contain. 

Suppose that we take the same iron as in the 
previous example, but, instead of not taking the 
full amount of iron, we make our mix the full 



—44— 

weight and see how near we would get at the cor- 
rect total Silicon. For simplicity sake, we drop 
the per cent Silicon, rembering that when we say 
the iron contains, for instance, 2.50, we mean 
2.50 per cent Silicon. 

Let us assume the following mixture: 

30(0 pounds gates at 2.20 .... 660 

200 pounds gates at 2.00 400 

200 pounds gates at 1.75 350 

300 pounds gates at 3.40i 1020 



1000 2430 

We see that our total weight is 1000' pounds, 
but the total Silicon is not 2500, but 2430, or it 
is 70 short. The mixture is too low in Silicon, 
and we must take more of the 3.40 and less of 
the 1.75. 

Now, if we take one pound more of the 3.40 
and one pound less of the 1.75, we do not change 
th'e weight, but we increase the Silicon. One 
pound more of 3.40 and one pound less of 1.75 
would increase the mix 3.40 — 1.75, equals 1.65. 
We want to increase the mix 70i; so that if one 
pound changes the mix 1.65, then, to change it 
to 70. we must change as many pounds as it re- 
quires to make 70, or 70 divided by 1.65 equals 
42.424. We will then have to increase the 3.40 
iron 42.43 pounds and decrease the 1.75 the 
same amount, and we^ have the same results as 
we have calculating the amounts the last method. 



—45— 

. Had our assumed mix been greater than the 
required amount, we would decrease the higher 
Silicon iron and take more of the low Silicon 
iron. 

Let us suppose the Phosphorus of the iron to 
be as follows: 

'2.2.0 Gates 93 

3.40 per cent Silicon iron to be 1.40 per ct. Phos 
2.00 per cent Silicon iron to be .80 per ct. Phos 
1 . 75 per cent Silicon iron to be . 50 per ct. Phos 

Then the mixture would be as follows: 

300 pounds gates @ . 93 equals ..2.79 
200 pounds 2.00 @ 1.60 equals. .1.20 
150 pounds 1 . 75 @ .50 equals . . .75 
350 pounds 3.40 @ 1.30 equals. .4.55 



1000 9.29 

Or an average of .93 per cent Phosphorus. 

If the mixture was to have been lower in Phos- 
phorus, then less of the high Phosphorus iron 
would have to be used, and in case the Phosphor- 
us was to have been higher more of the high 
Phosphorus iron would have to be used. 

Another example: 

To make a mixture of 1500 pounds at 3 per 
cent Silicon. 



—46— 

The total Silicon of this mixture would be 
1500- times 3 per cent, which is equal to 4500 
per cent. 

We will assume the following mixture as a 
trial, and see how near we come to the correct 
-amounts to be used. 

Per Ct. Per Ct. 

400 pounds of gates @ 2.70 equals. . .1080 
200" pounds of iron @ 1.82 equals. ... 364 

150 pounds of iron @ 2.00 equals 300 

200 pounds of iron @ 2.43 equals 486 

100 pounds of iron @ 3.10 equals... . 310 

150 pounds of iron @ 3.20 equals 480 

300 pounds of iron @ 4.50 equals 1350 



1500 4370 

15 pounds at 3.00 equals... .450*0 



130 
The total weight of the mixture is correct, but 
the total Silicon, instead of being 4500 per cent, 
is only 4370 per cent, or it is 130 per cent too 
low. The mixture must be increased in Silicon. 
One pound more of the 4.50 per cent and one 
pound less of the 3.20 per cent would increase 
the Silicon 4.50 per cent less 3.20 per cent, 
equals 1.30 per cent. To increase the mixture 
130 per cent it would take as many pounds as 
1.30 per cent is contained in 130 per cent, which. 
is 100. One hundred pounds more of the 4.50 



—47— 

per cent iron and 100 pounds less of the 3.20 
per cent iron would make the mix correct. 

Again. One pound more of the 4.50 per cent 
iron and one pound less of the 1.82- per cent 
would increase the Silicon 4.50 per cent less 1.82 
per cent, equals to 2.68 per cent. 

To increase the mixture 130 per cent it would 
take as many pounds as 2.68 per cent is con- 
tained in 130 per cent, which is 48.4 — practically 
50 pounds. We have made the change in each 
case by increasing one iron and taking the same 
amount less of another iron, changing the 
amounts in but two irons. We do not have to 
confine ourselves to two irons, but can take sev- 
eral irons. 

One pound more of the 4.50 per cent iron and 
one pound less of the 3.20 per cent iron woulcl 
increase the mixture 4.50' per cent less 3.20 per 
cent, equals to 1.30 per cent. Taking 50 pounds 
we would increase the mixture 50 times 1.30 
per cent, equals to 65 per cent. The total as- 
sumed mixture is 130 per cent too low, so that 
by this change we would still be 130 per cent 
less 65 per cent, equals to 65 per cent, too low. 

One pound more of 2.43 per cent iron and one 
pound less of 1.82 per cent iron would increase 
the mixture 2.43 per cent less 1.82 per cent, 
equals to .61 per cent. Taking 100 pounds, we 
would increase the mixture 100 times, .61 per 
cent, equals to 61 per cent. We would then be 



—48— 

65 per cent less 61 per cent, equals to 4 per cent, 
too low on the total mixture. This is calculating 
about as close as possible within 50 pounds. We 
have, however, two irons very near alike, namely, 
3.20' per cent and 3.10 per cent. One more of 
3.20 per cent and one pound less of 3.10 per cent 
would increase the mixture 3.20 per cent lesi* 
3.10 per cent, equals to 10 per cent. Fifty pounds 
more would increase the amount 50 times 10 per 
cent, equals to 5 per cent. The total Silicon of 
the mix would then be 5 per cent less 4 per cent, 
equals to 1 per cent too high. 

Notice that we took 50 pounds less of 3.20 per 
cent iron with the 4.50 per cent iron, and now 
take 50 pounds more of the 3.20' per cent iron 
with the 3.10 per cent iron, so that we might 
have taken the 4.50 per cent iron and the 3.10 
per cent. But we did not suppose to know this. 

This example illustrates very well how the 
method can be used. In assuming the amounts 
of iron, the total Phosphorus should be figured 
the same way as the total Silicon. As the Phos- 
phorus is too. high or too low, that will decide 
what changes had best be made. In the example 
given many more changes could have been made. 
Some irons might have been discarded alto- 
gether. The Phosphorus would determine that 
to a great extent. 



—49— 

Calculating the Mixture of Iron for Silicon, 
When More Than Two Irons are to be Used, 
by Making Separate Mixtures of Two Irons, 
and Combining These Separate Mixtures. 

We have had the method of calculating the 
mixture of iron for Silicon where two irons are 
to be used. The method is here used, and then 
the different mixtures are combined to make a 
grand total mixture. . Z "" 

To illustrate the method, let us suppose that 
we have three kinds of iron in the yard that 
analyzes 3.40 per cent, 2.00 per cent and 1.75 
per cent Silicon, and we want to make a casting 
that will contain 2.20 Silicon. Suppose that the 
loss in the cupola is .30 per cent; then the mix- 
ture would have to be 2.50» per cent Silicon. 

Now, by applying our rule for two cars at a 
time, we have the following calculation: 

Taking 3.40. and 2.00 we have 

High 3.40 Mix 2.50 .50). 90 (1.8 .90). 50 (.555 
Mix 2.50 Low 2 00 50 450 

.90 





.50 




400 




500 
450 

500 
450 


1. 


part 


of 3.40 


equals 


3.40 




1.8 


it 


" 2.03 


(C 


3 60 





2.8 " " 2.50 " 7.00 



—50— 

1. part of 2.00 equals 2.00 
1.55 " " 3.40 " 1.88 

1.55 " " 2.50 »« 3.88 

1 divided by 2.8 equals .357, or .357 parts of 
3.40 per cent and .643 parts 2.00. 

Taking the 3.40 and the 1.75 we have 

High 3 40 Mix 2.50 .90) .750 ( .833 .75). 90(1. 2 
Mix 2.50 Low 1.75 720 75 

.90 .75 300 150 

270 150 

300 
270 

300 

1 part of 3.40 equals 3.40 
1.2 " " 1.75 " 210 

2.2 2 50 5 50 

1 part of 1.75 equals 1.75 
.833 " " 3.40 " 2.83 



1.833 " " 250 " 4.58 

Dividing 1 by 2.2 equals .4546, hence .4546 
parts of 3.40 and .5454 parts of 1.75. If the cast-, 
ing is to be 2.50 per cent Silicon, then the gates 
or return scrap will be 2.20 per cent Silicon, 
which will require a higher Silicon iron to bring, 
it to 2.50 per cent. Taking, then, the gates witl 
the 3.40 per cent iron, we have 



—51— 

High 3.40 Mix 2.50 .90) .300 ( .333 

Mix 2.50 Gates 2.20 270 

.90 .30 300 

270 



30 



1 part of gates 2 20 equals 2.20 
.33 " " 3.40 " 1.13 

133 parts 2.50 " 3.38 

Dividing 1 by 1.333 equals .75, or .25 parts of 
3.40 and .75 parts of Gates. 

Taking one part to mean one pound we hare 
from the above: 

100' pounds of G-ates require 33.33 pounds of 
3.40 per cent Silicon iron. 

100 pounds of 2.00 per cent requires 55.55 
pounds of 3.40 per cent Silicon iron. 

100 pounds of 1.75 per cent requires 83.33 
pounds of 3.40 per cent Silicon iron. 

With two kinds of iron only one mixture can 
be made, but with two or more, and figuring for 
but one element, any amount of mixtures can be 
made. This is evident, for it is taken as granted 
that the first and second will make a mix and the 
first and third will make a mix. Now the 
amounts taken of these two mix to make a mix 
can vary almost inefinitely. Hence, in making a 
mix we must decide upon the amounts of some 



—52— 

of the irons and let the balance be taken as re 
quired to make the mix. 

To illustrate, let us suppose that we make i 
mix of 1000 pounds. We desire to use up o§ 
gates, which amount to 300 pounds a charge 
also want to use 300 pounds of the 2.00 per cen 
iron and the rest of 1.75 per cent and 3.40 pe: 
cent iron. From the above table we see that 

300 lbs. of gates require 1C0 lbs. of 3.40 per cent. 

200 lbs. of 2.00 per cent. Ill lbs. of 3.40 per cent. 

500 lbs. of iron require 211 lbs. of 3.40 per cen 
Or making a total of 711.11 pounds of iron. Th 
mixture is to contain 1000 pounds, so that w 
have 1000, minus 711.11 pounds, equals 288.8 
gates, to make with the 3.40 per cent iron an 
the 1.75 per cent. 

Looking up the 1.75 iron, we find that it r( 
quires .4546 of the 3.40 per cent and .5454 c 
the 1.75 per cent iron to make one part. Thei 
to make 288.90 parts, it will take 288.89 tinn 
this amount, or 131.33 of the 3.40 per cent au 
157.56 of the 1.75 per cent iron. 

Adding the three different amounts of 3.4 

per cent iron to be used, we have 341.83 pound 

The mixture, as calculated, will then be as fc 

lows : 

300 lb£. of gates at 2.20 660. 

200 " " iron " 2.00 400. 

157.56 175 27685 

342.44 3.40 1162.22 



1000 pounds of mix 2.50 2499.07 



—53— 

This is practically 2500, or average of 2.50 per 
cent. 

We find above that we use 157.56 of 1.75 per 
cent iron and 342.44 of 3.40i per cent iron. Now 
in practice we do not weigh so close, but only 
within an even 50 ponnds. Of course, every one 
can weigh as close as they see fit. It is always 
better to have the iron a little higher in Silicon 
than lower (chilled iron excepted); so we round 
off the mix above and call it 150 pounds of 1.75 
per cent and 3.50 of 3.40 per cent iron. The -mix 
will then be 

300 pounds of 2.20 per cent iron 
200 pounds of 2.00 per cent iron 
150 pounds of 1.75 per cent iron 
350 pounds of 3.40 per cent iron 

1000 

This will make the average about 2.51 per cent. 

If there had been another kind of iron that 
was above the mixture in Silicon, then this could 
have also been used. The main idea is to get the 
amount that is required with 100 pounds of iron 
and the amounts of each to make 100 pound?, 
and we have all that is required to make any mix. 

Calculating For Two Elements. 

It is impossible to calculate for more than one 
element at a time. If it is desired to figure the 
mixture for two elements, for instance, , Silicon 



—54— 

and Phosphorus, then two or more mixtures 
must first be figured for Silicon and these mix- 
tures taken and figured for Phosphorus. 

For Silicon it requires but two kinds of iron, 
but to figure for Silicon and Phosphorus it re- 
quires three or more kinds of iron, and the Phos- 
phorous in these irons must be so that when two 
of these irons are taken together the Phospho- 
rus of two of them will be above the require^ 
Phosphorus of the mix and the second two will 
be below the required Phosphorus of the mix. 

In the example for Silicon we had three kinds 
of iron. Let me take these same irons and give 
the Phosphorous: 

3.40 Silicon 1.40 per cent Phosphorus 
2.00 Silicon .80 per cent Phosphorus 

1.75 Silicon .50 per cent Phosphorus 

Taking the 3.40 per cent and 2.00) per cent, we 
see in the Silicon table that it takes .357 parts o' 
3.40 and .643 parts of 2.00. 

The Phosphorus in 100 pounds would then be 

3577 times 1.40 equals 49.98 
64.3 times .80 equals 51.44 



100 1101.42 

Mix would then be 2.50 Si.; 1.01 Phos. Call 
this "A." 

Taking 3.40 per cent and_1.75 per cent, we see 
from the Silicon table that it takes .4546 parts oj 
3.. 40 per cent and 5454 parts of 1.75 per cent. 



—55— 

The Phosphorus in 100 pounds would then be: 

45.46 times 1.40 equals 53.64 
54.54 times .50 equals 27.2? 



100. 80.91 

Mix would then be 2.50 per cent Silicon; .8091 
Phosphorus. Call this "B." 

Let us suppose the castings should be .93 per 
cent Phosphorus. Then, figuring the same way 
as in Silicon, we have : 



.014 
.93 


.93 
.809 


.084) 121 (.144 
84 


.121) 0840 (.694 
726 


.084 


.121 


370 
336 


1140 
1089 



1 part of .809 equals .809 
1.44 ; - ■« 1.469 " 1.460 

2.44 2 269 

1 part of 1.014 equals 1 014 
.694 " " .809 " .5614 

1 694 1.5764 

Dividing 1 by 2.44, we have .4098, hence .4098 
of .809 Phosphorus and .5902 of 1.014 Phospho- 
rus would make the mix. The mix would then be 
40.98 of "A" and 59.02 of "B." 

40.98A. .357 of 3 40 per cent equals 14.62986 
.643 of 2.00 " " " 26.35014 



—56— 

59,02B. .4546 of 3 40 per cent equals 26.830492 
.5454 u 1.75 '• " •' 32.189508 



lOO.OOOuOO 



Adding the two amountts of 3.40 per cent Sili- 
con, we have: 

41.460 of 3 40 per cent Silicon 1 40 per cent Phof 
26.350 of 2 00 " " " 80 " " " 

32 190 of 175 " " '« .50 " " " 

1000 000 of 2.00 " " " .93 " " " 

This is calculated to 100 pounds. Of course 
any amount could be taken by multiplying the 
above. If another iron was on hand, this coulc 
be figured like above and another mixture made 
This is all very easy, it being only a matter of , 
few figures. 

Any of the methods for calculating the Silicor 
can be used to make a mixture with the correc 
Silicon. The Phosphorus that these mixture 
contain must be calculated. Two or more mix 
tures are made and the Silicon item not consi( 
ered. The Phosphorus is then calculated th 
same manner as the Silicon has been. 



-^ 



Facts Worth Thinking About. 

By having analysis made you can tell whether 
the furnace sent you the iron ordered. 

By having each car checked the furnace will 
be more particular as to what they send you. 
Otherwise they are apt to think that you will not 
know any better. 

By analysis you can use the iron to the best 
advantage and save money. 

By analysis you can have the same mixture 
day after day and have better castings, changing 
your irons as you please. 

By analysis you are not dependent upon any 
particular brand, but can buy from whoever sells 
the cheapest. 

A ear of iron generally contains 25 tons of 
iron and costs between $400 and $500. Would 
not any one be willing to pay a dollar or two more 
to know that the iron is all right, and have the 
correct analysis so that the iron, can be used to 
the best advantage? 

Any foundryman that cannot save many, many 
times the cost of analysis ,in making the mixture, 
have better castings and less loss, had better 
give up his position. 



—58— 

SAMPLING IRON. 

Take three to six pieces (the more the better) 
of iron from different parts of the ear. If the iron 
is broken and the fracture can be seen, then se- 
lect different-looking pieces. Take borings of 
these pieces, throwing away the first cut, so that 
you get clean borings. Mix these borings well, 
and put about an ounce in a small envelope. On 
this envelope put the car number, name of iron 
or casting, or place any number or mark on it, 
so that you will know what it contains. Mark tne 
elements that you want analyzed on this en- 
velope. The same for any casting. I furnish a 
special printed envelope to my customers. Place 
this envelope or several envelopes in a large one 
and mail to 

WAUTEH H. WANGELIN, 

Chemist. Belleville, 111. 



— 59— 



tjsiei 



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Cincinniti. Chicago- Pittsburg. 

MANUFACTURES 

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HIGH GRADE PLUMBAGO 
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iff. LOUIS OFFICE, 305 Roe Building. 

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Telephones 
Bell, Main 2410. Kinloch, B 570. 



—GO— 
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-61- 



S3 

Blower Talk 



. To any foundry man needing a 
blower for curaola use we would 
recommend that, before buying else- 
where, you communicate with the 
COXXEKSYILLE BLOWEE CO., 
Connersville 3 Indiana, 

They are the manufacturers 
of a Eotary Positive Pressure Blow- 
er, which is being used very exten- 
sively in foundries and is giving ex- 
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A postal will bring you their cata" 
logue and prices will be quoted up- 
on application. They have also an 
Eastern office at 95 Liberty street, 
New York City, in charge of Mr. 
Horace G. Cooke. 



S3 



—62— 



De Camp Bros. & Yul 

IRON, GOAL X GOKE GO; 



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Sole agents for 

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Also high grade foundry iron for 
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—63— 

F. H. Cha.mberlin, President. J. D. Smith, Sec. and Treas 

THE 

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PROPRIETORS 



Cleveland Facing Mill 



-MANUFACTURERS OF— 



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